Innovative leaching techniques developed at Freeport have been vital to keeping its North America sites competitive despite economic and operational challenges, Kathleen Quirk said during a recent two-day Leach to the Last Drop summit in Phoenix.
What started a few years ago as imaginative ideas about how to extract more copper from existing stockpiles now is producing an annual run rate of more than 200 million pounds per year. That is expected to reach 300 to 400 million pounds by the end of 2026, with the eventual goal of achieving 800 million pounds annually. That is the equivalent of a major new mine without the associated capital and startup costs, said Quirk, President and Chief Executive Officer.
The success comes at a particularly important time when the company is dealing with cost inflation generally, and with longer haul runs and declining ore grades at some of its North America mines.
“I really believe we are on to something big here, really big that is going to change the industry and, of course, change Freeport,” Quirk told about 150 people who participated in the event held at the Hub in Phoenix. “If we didn’t have the results of your initiative, it would be really tough times right now. Even with it, our U.S. production has fallen every year for the last few years but now we are on the way back up, and that’s in large part to what you are doing.”
Copper recovered using the new leaching methods costs about $1 per pound, including capital and research expenses, about a third of what it costs using traditional methods in North America. Essentially, the project is paying for itself as the work advances. That makes it economically feasible to target the estimated 40 billion pounds of copper still unrecovered from old stockpiles.
Widespread turnout
The event brought together employees from a variety of specialties, including hydromet, exploration and mine planning to learn about the latest developments and share their own successes. Those attending came from all leaching sites in the Americas including Bagdad, Miami, Morenci, Safford, Sierrita, Chino, Tyrone, El Abra and Cerro Verde. Also participating were company leaders from Phoenix and members of Freeport’s Operational Improvement team that hosted the event.
Embracing innovation and applying emerging technology were recurring themes at the conference, which also included site updates and various breakout sessions. In addition, a number of employees were recognized during the conference for their important contributions to the effort. Those receiving awards included:
Mitchel “Buck” Umphres, Project Superintendent, received the Leadership Award, recognizing an individual “whose leadership continually pushes the organization forward.”
Guillermo Anguiano Chavez, Senior Innovation Engineer-Morenci, received the Innovation Award for helping make “notable improvements in our operations that impacted safety and/or production.”
Teno Siburian, Chief Geomechanical Engineer-Morenci, received the Collaboration Award for helping the organization “collectively solve problems across sites.”
Brandon Wellbrook, Senior Supervisor, Hydromet SX-Morenci, received the Frontline Award, recognizing “an individual from our front line that continually solves problems and innovates to push the organization forward.”
The Reagent Artificial Intelligence Team at the Tech Center in Safford received the Team Award for making “significant contributions to safety, production, or the enhancement of the Leach to the Last Drop effort.”
Abdel Madina, Metallurgist II-Sierrita, received the Stay the Course Award, recognizing an individual who “continually keeps the organization on track and achieving operational goals.”
Rosemary Blosser, Manager, Metallurgy-Phoenix, received the Lifetime Achievement Award, recognizing her contributions across her career.